Semiconductor system assemblies and methods of operation

ABSTRACT

An exemplary semiconductor processing system may include a remote plasma source coupled with a processing chamber having a top plate. An inlet assembly may be used to couple the remote plasma source with the top plate and may include a mounting assembly, which in embodiments may include at least two components. The inlet assembly may further include a precursor distribution assembly defining a plurality of distribution channels fluidly coupled with an injection port.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is related to U.S. application Ser. No. ______ (Attorney Docket No. 80042-890135 (114800US)) entitled “SEMICONDUCTOR SYSTEM ASSEMBLIES AND METHODS OF OPERATION,” and U.S. application Ser. No. ______ (Attorney Docket No. 80042-894191 (114802US)) entitled “SEMICONDUCTOR SYSTEM ASSEMBLIES AND METHODS OF OPERATION,” all of which being filed concurrently on Dec. 17, 2013, the entire disclosures of which are hereby incorporated by reference for all purposes.

TECHNICAL FIELD

The present technology relates to semiconductor systems, processes, and equipment. More specifically, the present technology relates to systems and methods for reducing film contamination and equipment degradation.

BACKGROUND

Integrated circuits are made possible by processes which produce intricately patterned material layers on substrate surfaces. Producing patterned material on a substrate requires controlled methods for removal of exposed material. Chemical etching is used for a variety of purposes including transferring a pattern in photoresist into underlying layers, thinning layers, or thinning lateral dimensions of features already present on the surface. Often it is desirable to have an etch process that etches one material faster than another facilitating, for example, a pattern transfer process. Such an etch process is said to be selective to the first material. As a result of the diversity of materials, circuits, and processes, etch processes have been developed with a selectivity towards a variety of materials.

Etch processes may be termed wet or dry based on the materials used in the process. A wet HF etch preferentially removes silicon oxide over other dielectrics and materials. However, wet processes may have difficulty penetrating some constrained trenches and also may sometimes deform the remaining material. Dry etches produced in local plasmas formed within the substrate processing region can penetrate more constrained trenches and exhibit less deformation of delicate remaining structures. However, local plasmas may damage the substrate through the production of electric arcs as they discharge.

Thus, there is a need for improved systems and methods that can be used to produce high quality devices and structures. These and other needs are addressed by the present technology.

SUMMARY

Systems, chambers, and processes are provided for controlling chamber degradation due to high voltage plasma. The systems may provide configurations for components that allow improved precursor distribution. The chambers may include modified components less likely to degrade due to exposure to plasma. The methods may provide for the limiting or prevention of chamber or component degradation as a result of etching processes performed by system tools.

Exemplary semiconductor processing systems may include a remote plasma source coupled with a processing chamber having a top plate. An inlet assembly may be used to couple the remote plasma source with the top plate and may include a mounting assembly, which in embodiments may include at least two components. The inlet assembly may further include a precursor distribution assembly defining a plurality of distribution channels fluidly coupled with an injection port.

A first component of the mounting assembly may include an annular gas block, and a second component of the mounting assembly may include a mounting block defining a channel and comprising a first mounting surface and a second mounting surface opposite the first mounting surface. In disclosed embodiments, a first section of the channel extending from the first mounting surface may be characterized by a first diameter. A second section of the channel extending from the first section of the channel to the second mounting surface may be characterized by an increasing diameter from the first section of the channel to the second mounting surface. In embodiments, the gas block may be coupled with a first surface of the precursor distribution assembly, and the mounting block may be coupled with a second surface of the precursor distribution assembly opposite the first surface of the precursor distribution assembly.

In embodiments, the precursor distribution assembly may comprise an annular shape. The precursor distribution assembly may include at least two coupled plates, which at least partially define the plurality of distribution channels. A first plate of the at least two coupled plates may at least partially define a first distribution channel extending tangentially from a single injection port to at least two secondary distribution channels. The at least two secondary distribution channels may extend tangentially from the first distribution channel to at least two tertiary distribution apertures. A second plate of the at least two coupled plates may at least partially define a portion of the at least two tertiary distribution apertures. The second plate may further define at least two tertiary distribution channels extending from the at least two tertiary distribution apertures. The second plate may further define at least two quaternary distribution channels extending from the at least two tertiary distribution channels.

Exemplary semiconductor processing systems according to the present technology may include a remote plasma source, and a processing chamber having a top plate. The systems may also include an inlet assembly coupling the remote plasma source with the top plate. The inlet assembly may include a precursor distribution assembly defining the plurality of distribution channels fluidly coupled with a single injection port. The precursor distribution assembly may also include at least two annular plates coupled with each other and at least partially defining a central distribution channel. A first plate of the at least two annular plates may define a single injection port and a first distribution channel tangentially extending from the single injection port. The second plate of the at least two annular plates may define at least two secondary distribution channels in fluid communication with the first distribution channel and the central distribution channel. The inlet assembly may further include a mounting assembly, and the mounting assembly may include at least two components spatially separated by the precursor distribution assembly. The semiconductor processing systems may also include a support assembly coupled with the remote plasma source and including at least one support extension extending from the support assembly towards the top plate. The support extension may be separated from the top plate in a first operational position, and the support extension may be configured to contact the top plate in a second operational position engageable during a processing operation.

Etching methods may be performed utilizing any of the disclosed technology, and the methods may include generating a plasma with a remote plasma source to create plasma effluents of a first precursor. The methods may also include bypassing the remote plasma source with a second precursor flowed into a gas distribution assembly. The gas distribution assembly may be fluidly coupled with the remote plasma source, such as with a central distribution channel. The methods may include contacting the second precursor with the plasma effluents of the first precursor to produce an etching formula. The contacting of the precursors may occur externally to a processing chamber. The methods may also include etching materials on a substrate housed in the processing chamber with the etching formula.

Such technology may provide numerous benefits over conventional systems and techniques. For example, degradation of chamber components may be prevented or limited due to external plasma generation. An additional advantage is that improved etching profiles may be provided based on improved precursor delivery. These and other embodiments, along with many of their advantages and features, are described in more detail in conjunction with the below description and attached figures.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of the disclosed technology may be realized by reference to the remaining portions of the specification and the drawings.

FIG. 1 shows a top plan view of an exemplary processing system according to the present technology.

FIG. 2 shows a schematic cross-sectional view of an exemplary processing chamber according to the present technology.

FIG. 3 shows a schematic cross-sectional view of a portion of an exemplary processing chamber according to the disclosed technology.

FIGS. 4A-B show schematic cross-sectional views of a portion of an exemplary distribution assembly according to the disclosed technology.

FIG. 5 shows a method of etching that may reduce film contamination according to the present technology.

Several of the Figures are included as schematics. It is to be understood that the Figures are for illustrative purposes, and are not to be considered of scale unless specifically stated to be as such.

In the appended figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the letter.

DETAILED DESCRIPTION

The present technology includes systems and components for semiconductor processing. When plasmas are formed in situ in processing chambers, such as with a capacitively coupled plasma (“CCP”) for example, exposed surfaces of the chamber may be sputtered or degraded by the plasma or the species produced by the plasma. This may in part be caused by bombardment to the surfaces or surface coatings by generated plasma particles. The extent of the bombardment may itself be related to the voltage utilized in generating the plasma. For example, higher voltage may cause higher bombardment, and further degradation.

Conventional technologies have often dealt with this degradation by providing replaceable components within the chamber. Accordingly, when coatings or components themselves are degraded, the component may be removed and replaced with a new component that will in turn degrade over time. However, the present systems may at least partially overcome or reduce this need to replace components by utilizing external plasma generation. Remote plasma sources may provide multiple benefits over internal plasma sources. For example, the remote plasma chamber core may be coated or composed of material specifically selected based on the plasma being produced. In this way, the remote plasma unit or components of the remote plasma unit such as the electrode may be protected to reduce wear and increase system life. Some conventional technologies utilizing remote plasma systems have reduced operational performance due to recombination of the plasma effluents based on longer flow paths. The present technology, however, may additionally overcome such issues by utilizing an inlet distribution system that reduces the length of travel for plasma species, as well as by allowing the generated plasma effluents to interact with other precursors nearer to the plasma source. Accordingly, the systems described herein provide improved performance and cost benefits over many conventional designs. These and other benefits will be described in detail below.

Although the remaining disclosure will routinely identify specific etching processes utilizing the disclosed technology, it will be readily understood that the systems and methods are equally applicable to deposition and cleaning processes as may occur in the described chambers. Accordingly, the technology should not be considered to be so limited as for use with etching processes alone.

FIG. 1 shows a top plan view of one embodiment of a processing system 100 of deposition, etching, baking, and curing chambers according to embodiments. The processing tool 100 depicted in FIG. 1 may contain a plurality of process chambers, 114A-D, a transfer chamber 110, a service chamber 116, an integrated metrology chamber 117, and a pair of load lock chambers 106A-B. The process chambers may include structures or components similar to those described in relation to FIG. 2, as well as additional processing chambers.

To transport substrates among the chambers, the transfer chamber 110 may contain a robotic transport mechanism 113. The transport mechanism 113 may have a pair of substrate transport blades 113A attached to the distal ends of extendible arms 113B, respectively. The blades 113A may be used for carrying individual substrates to and from the process chambers. In operation, one of the substrate transport blades such as blade 113A of the transport mechanism 113 may retrieve a substrate W from one of the load lock chambers such as chambers 106A-B and carry substrate W to a first stage of processing, for example, an etching process as described below in chambers 114A-D. If the chamber is occupied, the robot may wait until the processing is complete and then remove the processed substrate from the chamber with one blade 113A and may insert a new substrate with a second blade (not shown). Once the substrate is processed, it may then be moved to a second stage of processing. For each move, the transport mechanism 113 generally may have one blade carrying a substrate and one blade empty to execute a substrate exchange. The transport mechanism 113 may wait at each chamber until an exchange can be accomplished.

Once processing is complete within the process chambers, the transport mechanism 113 may move the substrate W from the last process chamber and transport the substrate W to a cassette within the load lock chambers 106A-B. From the load lock chambers 106A-B, the substrate may move into a factory interface 104. The factory interface 104 generally may operate to transfer substrates between pod loaders 105A-D in an atmospheric pressure clean environment and the load lock chambers 106A-B. The clean environment in factory interface 104 may be generally provided through air filtration processes, such as HEPA filtration, for example. Factory interface 104 may also include a substrate orienter/aligner (not shown) that may be used to properly align the substrates prior to processing. At least one substrate robot, such as robots 108A-B, may be positioned in factory interface 104 to transport substrates between various positions/locations within factory interface 104 and to other locations in communication therewith. Robots 108A-B may be configured to travel along a track system within enclosure 104 from a first end to a second end of the factory interface 104.

The processing system 100 may further include an integrated metrology chamber 117 to provide control signals, which may provide adaptive control over any of the processes being performed in the processing chambers. The integrated metrology chamber 117 may include any of a variety of metrological devices to measure various film properties, such as thickness, roughness, composition, and the metrology devices may further be capable of characterizing grating parameters such as critical dimensions, sidewall angle, and feature height under vacuum in an automated manner.

Turning now to FIG. 2 is shown a cross-sectional view of an exemplary process chamber system 200 according to the present technology. Chamber 200 may be used, for example, in one or more of the processing chamber sections 114 of the system 100 previously discussed Generally, the etch chamber 200 may include a first capacitively-coupled plasma source to implement an ion milling operation and a second capacitively-coupled plasma source to implement an etching operation and to implement an optional deposition operation. The chamber 200 may include grounded chamber walls 240 surrounding a chuck 250. In embodiments, the chuck 250 may be an electrostatic chuck that clamps the substrate 202 to a top surface of the chuck 250 during processing, though other clamping mechanisms as would be known may also be utilized. The chuck 250 may include an embedded heat exchanger coil 217. In the exemplary embodiment, the heat exchanger coil 217 includes one or more heat transfer fluid channels through which heat transfer fluid, such as an ethylene glycol/water mix, may be passed to control the temperature of the chuck 250 and ultimately the temperature of the substrate 202.

The chuck 250 may include a mesh 249 coupled to a high voltage DC supply 248 so that the mesh 249 may carry a DC bias potential to implement the electrostatic clamping of the substrate 202. The chuck 250 may be coupled with a first RF power source and in one such embodiment, the mesh 249 may be coupled with the first RF power source so that both the DC voltage offset and the RF voltage potentials are coupled across a thin dielectric layer on the top surface of the chuck 250. In the illustrative embodiment, the first RF power source may include a first and second RF generator 252, 253. The RF generators 252, 253 may operate at any industrially utilized frequency, however in the exemplary embodiment the RF generator 252 may operate at 60 MHz to provide advantageous directionality. Where a second RF generator 253 is also provided, the exemplary frequency may be 2 MHz.

With the chuck 250 to be RF powered, an RF return path may be provided by a first showerhead 225. The first showerhead 225 may be disposed above the chuck to distribute a first feed gas into a first chamber region 284 defined by the first showerhead 225 and the chamber wall 240. As such, the chuck 250 and the first showerhead 225 form a first RF coupled electrode pair to capacitively energize a first plasma 270 of a first feed gas within a first chamber region 284. A DC plasma bias, or RF bias, resulting from capacitive coupling of the RF powered chuck may generate an ion flux from the first plasma 270 to the substrate 202, e.g., Ar ions where the first feed gas is Ar, to provide an ion milling plasma. The first showerhead 225 may be grounded or alternately coupled with an RF source 228 having one or more generators operable at a frequency other than that of the chuck 250, e.g., 13.56 MHz or 60 MHz. In the illustrated embodiment the first showerhead 225 may be selectably coupled to ground or the RF source 228 through the relay 227 which may be automatically controlled during the etch process, for example by a controller (not shown). In disclosed embodiments, chamber 200 may not include showerhead 225 or dielectric spacer 220, and may instead include only baffle 215 and showerhead 210 described further below.

As further illustrated in the figure, the etch chamber 200 may include a pump stack capable of high throughput at low process pressures. In embodiments, at least one turbo molecular pump 265, 266 may be coupled with the first chamber region 284 through one or more gate valves 260 and disposed below the chuck 250, opposite the first showerhead 225. The turbo molecular pumps 265, 266 may be any commercially available pumps having suitable throughput and more particularly may be sized appropriately to maintain process pressures below or about 10 mTorr or below or about 5 mTorr at the desired flow rate of the first feed gas, e.g., 50 to 500 sccm of Ar where argon is the first feedgas. In the embodiment illustrated, the chuck 250 may form part of a pedestal which is centered between the two turbo pumps 265 and 266, however in alternate configurations chuck 250 may be on a pedestal cantilevered from the chamber wall 240 with a single turbo molecular pump having a center aligned with a center of the chuck 250.

Disposed above the first showerhead 225 may be a second showerhead 210. In one embodiment, during processing, the first feed gas source, for example, Argon delivered from gas distribution system 290 may be coupled with a gas inlet 276, and the first feed gas flowed through a plurality of apertures 280 extending through second showerhead 210, into the second chamber region 281, and through a plurality of apertures 282 extending through the first showerhead 225 into the first chamber region 284. An additional flow distributor or baffle 215 having apertures 278 may further distribute a first feed gas flow 216 across the diameter of the etch chamber 200 through a distribution region 218. In an alternate embodiment, the first feed gas may be flowed directly into the first chamber region 284 via apertures 283 which are isolated from the second chamber region 281 as denoted by dashed line 223.

Chamber 200 may additionally be reconfigured from the state illustrated to perform an etching operation. A secondary electrode 205 may be disposed above the first showerhead 225 with a second chamber region 281 there between. The secondary electrode 205 may further form a lid or top plate of the etch chamber 200. The secondary electrode 205 and the first showerhead 225 may be electrically isolated by a dielectric ring 220 and form a second RF coupled electrode pair to capacitively discharge a second plasma 292 of a second feed gas within the second chamber region 281. Advantageously, the second plasma 292 may not provide a significant RF bias potential on the chuck 250. At least one electrode of the second RF coupled electrode pair may be coupled with an RF source for energizing an etching plasma. The secondary electrode 205 may be electrically coupled with the second showerhead 210. In an exemplary embodiment, the first showerhead 225 may be coupled with a ground plane or floating and may be coupled to ground through a relay 227 allowing the first showerhead 225 to also be powered by the RF power source 228 during the ion milling mode of operation. Where the first showerhead 225 is grounded, an RF power source 208, having one or more RF generators operating at 13.56 MHz or 60 MHz, for example, may be coupled with the secondary electrode 205 through a relay 207 which may allow the secondary electrode 205 to also be grounded during other operational modes, such as during an ion milling operation, although the secondary electrode 205 may also be left floating if the first showerhead 225 is powered.

A second feed gas source, such as nitrogen trifluoride, and a hydrogen source, such as ammonia, may be delivered from gas distribution system 290, and coupled with the gas inlet 276 such as via dashed line 224. In this mode, the second feed gas may flow through the second showerhead 210 and may be energized in the second chamber region 281. Reactive species may then pass into the first chamber region 284 to react with the substrate 202. As further illustrated, for embodiments where the first showerhead 225 is a multi-channel showerhead, one or more feed gases may be provided to react with the reactive species generated by the second plasma 292. In one such embodiment, a water source may be coupled with the plurality of apertures 283.

In an embodiment, the chuck 250 may be movable along the distance H2 in a direction normal to the first showerhead 225. The chuck 250 may be on an actuated mechanism surrounded by a bellows 255, or the like, to allow the chuck 250 to move closer to or farther from the first showerhead 225 as a means of controlling heat transfer between the chuck 250 and the first showerhead 225, which may be at an elevated temperature of 80° C.-150° C., or more. As such, an etch process may be implemented by moving the chuck 250 between first and second predetermined positions relative to the first showerhead 225. Alternatively, the chuck 250 may include a lifter 251 to elevate the substrate 202 off a top surface of the chuck 250 by distance H1 to control heating by the first showerhead 225 during the etch process. In other embodiments, where the etch process is performed at a fixed temperature such as about 90-110° C. for example, chuck displacement mechanisms may be avoided. A system controller (not shown) may alternately energize the first and second plasmas 270 and 292 during the etching process by alternately powering the first and second RF coupled electrode pairs automatically.

The chamber 200 may also be reconfigured to perform a deposition operation. A plasma 292 may be generated in the second chamber region 281 by an RF discharge which may be implemented in any of the manners described for the second plasma 292. Where the first showerhead 225 is powered to generate the plasma 292 during a deposition, the first showerhead 225 may be isolated from a grounded chamber wall 240 by a dielectric spacer 230 so as to be electrically floating relative to the chamber wall. In the exemplary embodiment, an oxidizer feed gas source, such as molecular oxygen, may be delivered from gas distribution system 290, and coupled with the gas inlet 276. In embodiments where the first showerhead 225 is a multi-channel showerhead, any silicon-containing precursor, such as OMCTS for example, may be delivered from gas distribution system 290, and directed into the first chamber region 284 to react with reactive species passing through the first showerhead 225 from the plasma 292. Alternatively the silicon-containing precursor may also be flowed through the gas inlet 276 along with the oxidizer.

FIG. 3 shows a schematic cross-sectional view of a portion of an exemplary processing system 300 according to the disclosed technology. As illustrated, system 300 includes a more detailed view of an exemplary version of a top portion and related components of, for example, system 200 as previously described. System 300 includes a variety of components that may be utilized to deliver precursors to a processing chamber 307 through top plate 310, which may be similar in aspects to top plate or cover 205 as previously described. Semiconductor processing system 300 may include remote plasma source 305 that may be configured to produce plasma effluents external to processing chamber 307. Plasma effluents produced in remote plasma source 305 may include a variety of reactive and nonreactive species that may include one or more precursors including argon, helium, hydrogen, nitrogen, and additional inert or reactive precursors. Once generated by remote plasma source 305, the effluents may be delivered to the processing chamber through an inlet assembly coupling the remote plasma source with the top plate 310 of the semiconductor processing chamber 307.

The inlet assembly may include a mounting assembly which may have at least two components in disclosed embodiments. A first component of an exemplary mounting assembly may include a gas block 315 which at least partially defines a central distribution channel 303 through which plasma effluents and/or precursors may be delivered to processing chamber 307. Gas block 315 may be annular in shape and may include extended support sections 317 that may provide both an increased mating platform as well as improved structural support for a larger power supply such as remote plasma source 305. A second component of the mounting assembly may include mounting block 325 further defining at least a portion of the central distribution channel 303 of the inlet assembly. Mounting block 325 may include a first mounting surface 326 and a second mounting surface 327 opposite the first mounting surface 326. In embodiments, mounting block 325 may also include extended support sections 328 providing both an increased mating platform as well as improved structural support.

Portions of mounting block 325 may define multiple sections of central distribution channel 303, and may define similar or different shapes of the channel from each other. For example, a first section 330 of mounting block 325 may define a first section of the central distribution channel 303 extending from the first mounting surface 326 to an intermediate portion of mounting block 325. In embodiments the first section 330 of mounting block 325 may be characterized by a cylindrical shape, or the section may be characterized by a first diameter. A second section 335 of mounting block 325 may be characterized by a similar or different shape than first section 330 of mounting block 325. In embodiments, second section 335 of mounting block 325 may define a second section of central distribution channel 303 extending from the intermediate portion of mounting block 325 to the second mounting surface 327. Second section 335 of mounting block 325 may be characterized by a conical shape, or may be characterized by an increasing diameter at least partially along the intermediate portion of mounting block 325 to the second mounting surface 327.

The inlet assembly coupling the remote plasma source with the top plate 310 may further include a precursor distribution assembly 320 defining a plurality of distribution channels fluidly coupled with an injection port 322, which may be a single injection port in disclosed embodiments. As illustrated, injection port 322 may be fluidly coupled with a precursor injection line 324 configured to provide precursors which may bypass remote plasma source 305. Precursor distribution assembly 320 will be discussed in greater detail below with reference to FIGS. 4A-4B. Precursor distribution assembly 320 may include a first surface 321 which may be coupled with gas block 315. Precursor distribution assembly 320 may further include a second surface 323 opposite first surface 321 and coupled with mounting block 325. In this way, the two components of the mounting assembly may be spatially separated by the precursor distribution assembly 320.

Mounting block 325 may be coupled with processing chamber 307 in a variety of ways, one embodiment of which is illustrated in FIG. 3. Top plate 310 may include a first surface 309 in which an opening 312 is defined. Top plate 310 may also include a second surface 311 opposite the first surface 309. Opening 312 may be defined in top plate 310 from upper surface 309 to a lower surface 314 of opening 312. Top plate 310 may further define a plurality of outlet distribution channels 316 defined from the lower surface 314 of opening 312 to the second surface 311 of top plate 310, providing fluid communication with processing chamber 307. Outlet distribution channels 316 may be distributed through top plate 310 in a variety of patterns and may be configured to provide a more uniform flow into processing chamber 307. Within opening 312, top plate 310 may further define a ledge 313 on which mounting block 325 may be seated. Within ledge 313 one or more o-rings 340 may be included to provide a seal between the inlet assembly via mounting block 325 and chamber 307 via top plate 310.

Many conventional power supplies utilized in plasma generation may provide power down below 100 kHz, 10 kHz, or less. Such power supplies often have a smaller footprint along with a lower weight of the electrical source itself. Modifying the system to accommodate the remote plasma source 305 may require significant modifications to the inlet assembly to accommodate not only the larger size, but also the increased weight of the supply itself. Embodiments of the present technology may be specifically configured to accommodate such a remote plasma source as will be described in detail herein.

In order to accommodate the increased size and weight of the high-frequency electrical source 305, semiconductor processing system 300 may further include support assembly 350 in order to properly balance and support remote plasma source 305. The support assembly 350 may include any number of mounting plates or other structural devices in order to provide such balance and support. Support assembly 350 coupled with the remote plasma source 305 may additionally include floating supports 355 that may provide further support in stabilization during system operation. In embodiments the support assembly may include at least one, e.g. 1, 2, 3, 4, 8, 12, 20, etc. or more, support extension 355 extending from the support assembly 350 towards top plate 310. Support extensions 355 may include a variety of shapes configured for bearing the weight of remote plasma source 305, and as illustrated in FIG. 3, may include an S-shape in disclosed embodiments.

Support extensions 355 may be separated from top plate 310 in a first operational position in disclosed embodiments. Such a first operational position is illustrated in FIG. 3 and shows a gap between the support extensions 355 and top plate 310. Although illustrated as a defined gap in FIG. 3, it is to be understood that the first operational position may include any degree of spacing between the support extensions 355 and top plate 310 including a first degree of contact between the structures. Support extensions 355 may be utilized and configured to contact top plate 310 in a second operational position engageable during a processing operation.

As previously discussed, o-rings 340 may be used in the coupling of mounting block 325 with top plate 310, and may aid in reducing leakage during operation, which may occur under vacuum conditions. Compression of o-rings 340 may occur both from vacuum conditions as well as from the weight of remote plasma source 305. In such case, o-rings 340 may compress to an extent to allow support extensions 355 to engage top plate 310 of chamber 307 in the discussed second operational position. In a situation in which support extensions 355 contact top plate 310 in the first operational position, the second operational position may be differentiated from the first operational position by a second degree of contact between the support extensions 355 and top plate 310. In such a situation the second degree of contact may be greater or at a higher force than the first degree of contact, and may be due at least in part to vacuum conditions enacted during a processing operation. Support extensions 355 may then in turn reduce strain on the inlet assembly components as well as aid in reducing vibration during operation.

Turning to FIGS. 4A and 4B, shown are schematic cross-sectional views of a portion of an exemplary precursor distribution assembly 400 according to the disclosed technology, which includes a detailed view of an embodiment of precursor distribution assembly 320 previously described. As illustrated in FIGS. 4A-4B, the precursor distribution assembly 400 may include one or more plates, such as two plates 405, 450 as illustrated, and may include an annular shape defining at least a portion of the central distribution channel. In embodiments the precursor distribution assembly 400 may include up to or more than 1, 2, 3, 4, 5, 7, 10, etc. or more plates coupled together to produce the precursor distribution assembly 400. As illustrated, the figures show a view of the precursor distribution assembly from the position of a remote plasma source, such as remote plasma source 305 previously described, and including a view of outlet distribution channels 498, or in disclosed embodiments apertures of a baffle plate or showerhead included within a processing chamber. In disclosed embodiments the precursor distribution assembly 400 may include at least two coupled plates, which at least partially define a plurality of distribution channels as will be described below.

FIG. 4A illustrates a view of a first plate 405 which may be located proximate a gas block, such as gas block 315 previously described. First plate 405 may be annular in shape including an inner diameter 407 and an outer diameter 408. First plate 405 may additionally define at least a portion of a central distribution channel 409 which may be similar to the central distribution channel 303 previously described. In disclosed embodiments first plate 405 may be characterized by shapes other than an annular shape.

First plate 405 may define an inlet port 410, which may be similar to the precursor injection port 322 previously described. Inlet port 410 may provide access to a fluid delivery channel 412 also defined in first plate 405. When coupled with a precursor source, such a configuration may provide a way in which the precursor may be distributed to a processing chamber while bypassing a remote plasma source. Delivery channel 412 may be fluidly coupled with a first distribution channel 415 defined between the inner diameter 407 and outer diameter 408, and extending tangentially from delivery channel 412 and injection port 410. First distribution channel 415 may at least partially extend about an interior circumference of first plate 405. In embodiments first distribution channel 415 extends bidirectionally about such a circumference from delivery channel 412, and may extend up to a full circumference of the interior circumference. As illustrated in FIG. 4A, first distribution channel 415 may extend partially about the interior circumference, and may extend up to about 25%, about 50%, about 75%, or any other percent up to 100% of the full circumference. In embodiments first distribution channel 415 may extend about 50% of an interior circumference, or about 25% in each direction from delivery channel 412, before extending to at least two secondary distribution channels 420, 430.

Secondary distribution channels 420, 430 may extend in a similar or different fashion than the first distribution channel 415 from delivery channel 412. As illustrated, secondary distribution channels 420, 430 may extend bidirectionally from distal portions of first distribution channel 415 about a second interior circumference of first plate 405 that is smaller than the first interior circumference. Secondary distribution channels 420, 430 may extend partially about the second interior circumference, and may extend up to about 25%, about 50%, about 75%, or any other percent up to 100% of the full second interior circumference. In one embodiment as illustrated in FIG. 4A, secondary distribution channels 420, 430 each extend less than about 30% of the full circumference of the second interior circumference.

Each secondary distribution channel 420, 430 may extend about the second interior circumference to two positions, such as positions 422, 424 as illustrated for second distribution channel 420. The secondary distribution channels may extend tangentially from first distribution channel 415 to at least two tertiary distribution apertures, such as apertures 425A, 427A as illustrated in FIG. 4A for secondary distribution channel 420. The tertiary distribution apertures may be located at distal portions of the secondary distribution channels, and may be proximate the end positions, such as proximate positions 422, 424 as illustrated. The tertiary distribution apertures may be at least partially defined by top plate 405, and may provide access to second plate 450. Although circumference is used in reference to a generally circular shape, it is understood that alternative geometries may be used for the distribution channels, and circumference may generally refer to a perimeter of such geometries.

FIG. 4B illustrates a view of a second plate 450 which may be located proximate a mounting block, such as mounting block 325 previously described. Second plate 450 may be annular in shape including an inner diameter 452 and an outer diameter 454. Second plate 450 may additionally define at least a portion of a central distribution channel 456 which may be similar to the central distribution channel 303 previously described. In disclosed embodiments second plate 450 may be characterized by shapes other than an annular shape.

Second plate 450 may at least partially define a portion of at least two tertiary distribution apertures 425B, 427B, which may provide fluid communication between first plate 405 and second plate 450 via the coupled tertiary distribution apertures, which may be partially defined by each plate. Second plate 450 may also at least partially define at least two tertiary distribution channels extending from the at least two tertiary distribution apertures. As illustrated in FIG. 4B, four tertiary distribution channels 432, 434, 436, 438 are illustrated extending into a third interior circumference that may be equal to, greater than, or less than the second interior circumference. Each tertiary distribution channel may extend bidirectionally from a tertiary distribution aperture about the third interior circumference. Each tertiary distribution channel may extend partially about the third interior circumference, and may extend up to about 25%, about 50%, about 75%, or any other percent up to 100% of the full third interior circumference. In disclosed embodiments, each tertiary distribution channel extends less than about 25% of the third interior circumference,

Second plate 450 may further define at least two quaternary distribution channels extending from the at least two tertiary distribution channels. As illustrated in FIG. 4B, second plate 450 defines at least one quaternary distribution channel 440 extending from each tertiary distribution channel, and in embodiments a plurality of quaternary distribution channels 440 extend from each tertiary distribution channel. Quaternary distribution channels 440 may extend to inner diameter 452 and provide access to the at least partially defined central distribution channel 456. Accordingly, as illustrated in the two schematics the precursor distribution assembly 400 may define a plurality of distribution channels fluidly coupled with a single injection port, where the precursor distribution assembly includes at least two annular plates coupled with each other and at least partially defining a central distribution channel.

A first plate of the at least two annular plates may define a fluid injection port as well as a first distribution channel tangentially extending from this injection port. A second plate of the at least two annular plates defines at least two secondary distribution channels, such as the tertiary and quaternary distribution channels discussed, where the secondary distribution channels are in fluid communication with the first distribution channel and the central distribution channel to provide an injected fluid substantially uniformly to the central distribution channel. This distribution configuration may provide a number of benefits over conventional schemes. For example, precursor mixing between a radicalized precursor provided by a remote plasma source and a non-radicalized precursor provided through the injection port of the precursor distribution assembly may occur prior to the precursors entering the processing chamber. In this way, less recombination may occur from the radicalized species because of the shorter flow path provided by this design. Additionally, the precursor distribution assembly may provide improved and more uniform interaction between the precursors based on the distribution channels within the precursor distribution assembly providing the injected precursor more uniformly across the central distribution channel.

FIG. 5 shows a method 500 of etching that may reduce film contamination and provide more uniform precursor distribution according to the present technology. Method 500 may be performed in any of the systems previously described and may include optional operations including delivering a precursor for ionization to a remote plasma source. Method 500 may include generating a plasma within a remote plasma source to create plasma effluents of the first precursor in operation 510. The remote plasma source may operate in a variety of plasma powers including up to 1000 Watts, 6000 Watts, 8000 Watts, 10,000 Watts, etc. or more. Method 500 may further include bypassing the remote plasma source with a second precursor flowed into a gas distribution assembly at operation 520. The gas distribution assembly may be fluidly coupled with a remote plasma source, such as via a central distribution channel.

Method 500 may also include contacting the second precursor with the plasma effluents of the first precursor to produce an etching formula at operation 530. Contacting the precursors may occur externally to a processing chamber in which the etching may be performed, such as in the central distribution channel. At operation 540, after allowing the precursors to interact, the etching formula may be flowed into a processing chamber in which a substrate may be housed, and materials on the substrate may be etched with the etching formula. By forming the plasma and plasma effluents externally to the processing chamber, degradation of chamber components or coatings may be reduced or prevented in embodiments. The sputtered particles may be carried through the system and deposited on the substrate being worked, which may result in short-circuiting or failure of the produced device. Accordingly, by utilizing the described methods increased device quality may be provided as well as increased chamber component life. Additionally, by utilizing a gas distribution assembly or precursor distribution assembly, such as those discussed previously, the methods may provide a more uniform distribution of the etching formula due to improved interaction and mixing provided in the central distribution channel. Consequently, more uniform etching may be performed on materials on the substrate, which may improve overall device quality.

In the preceding description, for the purposes of explanation, numerous details have been set forth in order to provide an understanding of various embodiments of the present technology. It will be apparent to one skilled in the art, however, that certain embodiments may be practiced without some of these details, or with additional details.

Having disclosed several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the embodiments. Additionally, a number of well-known processes and elements have not been described in order to avoid unnecessarily obscuring the present technology. Accordingly, the above description should not be taken as limiting the scope of the technology.

Where a range of values is provided, it is understood that each intervening value, to the smallest fraction of the unit of the lower limit, unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Any narrower range between any stated values or unstated intervening values in a stated range and any other stated or intervening value in that stated range is encompassed. The upper and lower limits of those smaller ranges may independently be included or excluded in the range, and each range where either, neither, or both limits are included in the smaller ranges is also encompassed within the technology, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included.

As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “an aperture” includes a plurality of such apertures, and reference to “the plate” includes reference to one or more plates and equivalents thereof known to those skilled in the art, and so forth.

Also, the words “comprise(s)”, “comprising”, “contain(s)”, “containing”, “include(s)”, and “including”, when used in this specification and in the following claims, are intended to specify the presence of stated features, integers, components, or operations, but they do not preclude the presence or addition of one or more other features, integers, components, operations, acts, or groups. 

1. A semiconductor processing system comprising: a remote plasma source; a processing chamber having a top plate; and an inlet assembly coupling the remote plasma source with the top plate and comprising: a mounting assembly, and a precursor distribution assembly defining a plurality of distribution channels fluidly coupled with an injection port.
 2. The semiconductor processing system of claim 1, wherein the mounting assembly comprises at least two components.
 3. The semiconductor processing system of claim 2, wherein a first component of the mounting assembly comprises an annular gas block.
 4. The semiconductor processing system of claim 3, wherein a second component of the mounting assembly comprises a mounting block defining a channel and comprising a first mounting surface and a second mounting surface opposite the first mounting surface.
 5. The semiconductor processing system of claim 4, wherein a first section of the channel extending from the first mounting surface is characterized by a first diameter.
 6. The semiconductor processing system of claim 5, wherein a second section of the channel extending from the first section of the channel to the second mounting surface is characterized by an increasing diameter at least partially along the first section of the channel towards the second mounting surface.
 7. The semiconductor processing system of claim 4, wherein the gas block is coupled with a first surface of the precursor distribution assembly and the mounting block is coupled with a second surface of the precursor distribution assembly opposite the first surface of the precursor distribution assembly.
 8. The semiconductor processing system of claim 1, wherein the precursor distribution assembly comprises an annular shape.
 9. The semiconductor processing system of claim 1, wherein the precursor distribution assembly comprises at least two coupled plates, which at least partially define the plurality of distribution channels.
 10. The semiconductor processing system of claim 9, wherein a first plate of the at least two coupled plates at least partially defines a first distribution channel extending tangentially from the single injection port to at least two secondary distribution channels.
 11. The semiconductor processing system of claim 10, wherein the at least two secondary distribution channels extend tangentially from the first distribution channel to at least two tertiary distribution apertures.
 12. The semiconductor processing system of claim 11, wherein a second plate of the at least two coupled plates at least partially defines a portion of the at least two tertiary distribution apertures, and wherein the second plate further defines at least two tertiary distribution channels extending from the at least two tertiary distribution apertures.
 13. The semiconductor processing system of claim 12, wherein the second plate further defines at least two quaternary distribution channels extending from the at least two tertiary distribution channels.
 14. A semiconductor processing system comprising: a remote plasma source; a processing chamber having a top plate; an inlet assembly coupling the remote plasma source with the top plate and comprising: a precursor distribution assembly defining a plurality of distribution channels fluidly coupled with a single injection port, wherein the precursor distribution assembly comprises at least two annular plates coupled with each other and at least partially defining a central distribution channel, wherein a first plate of the at least two annular plates defines the single injection port and a first distribution channel tangentially extending from the single injection port, and wherein a second plate of the at least two annular plates defines at least two secondary distribution channels in fluid communication with the first distribution channel and the central distribution channel, and a mounting assembly, wherein the mounting assembly comprises at least two components spatially separated by the precursor distribution assembly; and a support assembly coupled with the remote plasma source and including at least one support extension extending from the support assembly towards the top plate, wherein the at least one support extension is separated from the top plate in a first operational position, and wherein the at least one support extension is configured to contact the top plate in a second operational position engageable during a processing operation.
 15. An etching method, the method comprising: generating a plasma with a remote plasma source to create plasma effluents of a first precursor; bypassing the remote plasma source with a second precursor flowed into a gas distribution assembly, wherein the gas distribution assembly is fluidly coupled with the remote plasma source; contacting the second precursor with the plasma effluents of the first precursor to produce an etching formula, wherein the contacting occurs externally to a processing chamber; and etching materials on a substrate housed within the processing chamber with the etching formula. 